Emission control devices for air intake systems

ABSTRACT

An air intake emission control device includes a self -forming adsorbing element ( 200 ) comprising a front edge ( 301 ), a back edge ( 302 ), side edges ( 303 ) extending between the front and back edges and defining an air intake flow path, and a first locking component ( 301   a ) on the front edge, back edge, or both. The device further includes a second locking component ( 403 ) configured to engage the first locking component and retain the self-forming adsorbing element in a predetermined structure. The second locking component may be located on the adsorbing element itself such that the adsorbing element is self-formed and self-locked in the predetermined structure. Alternatively, the device may include an end cap ( 401 ) and the second locking structure may be located on the end cap. The device may be placed in air intake ductwork, in an extending conduit positioned between the an air intake ductwork and the air outlet ductwork, or both.

BACKGROUND OF THE DISCLOSURE

An increase in environmental concerns has continued to drive strict regulations of the hydrocarbon emissions from automotives into the environment, even when the vehicle is not operating. The great majority of internal combustion engines in use today are fuel-injected engines. When a fuel-injected engine is switched off after use, a small amount of residual fuel volatilizes and escapes from the injector tips. While a vehicle is sitting over time after use, this evaporated fuel may pass outwardly through the intake manifold, the intake air ducts and air filter, and may escape into an atmosphere contributing to air pollution. Therefore, it would be desirable to minimize this type of inadvertent evaporative emissions leakage.

One approach to abate the hydrocarbon emissions from the intake manifold after an engine shutdown is to use an air intake filter-like device having a hydrocarbon adsorbing element. One drawback of these air intake emission control devices is that the devices may act as an obstruction to the air flowing to the engine, thus causing a pressure drop in the airflow to the engine.

U.S. Patent Publication No. 2004/0099253 discloses an emission control device for an engine air induction system. The device comprises an adsorbing element being shaped to conform to the shape of an air intake ductwork with the adsorbent material forming the walls of the element.

U.S. Pat. No. 7,168,417 describes a hydrocarbon trapping device for an engine's air intake system comprising: a conduit in fluid connection with the air intake system and including a wall; an adsorbing element positioned within the conduit wall; and a retainer extending from an inner surface of the conduit wall. The adsorbing element includes a leading edge, a trailing edge and side edges defining a flow path extending between the leading and trailing edges. The retainer engages the side edges of the absorbing element and secures the adsorbing element within the conduit wall.

U.S. Pat. No. 7,222,612 describes a low-resistance hydrocarbon-adsorptive cartridge for an air intake system of internal combustion engine, comprising a housing having art opening for air intake passage and a hydrocarbon-adsorptive sheet positioned within the housing and across the opening. A plurality of radial retainers is used to form the adsorptive sheet into a spiral structure disposed within the opening of the housing and to maintain the spacing between the convolutions of the spiral structure. Alternatively, the convolutions of the adsorbent sheet are formed by using a plurality of individual concentric cylindrical sheet elements.

SUMMARY OF THE DISCLOSURE

An air intake emission control device includes a self-forming adsorbing element comprising a front edge, a back edge, side edges extending between the front and back edges and defining an air intake flow path, and a first locking component on the front edge, back edge, or both. The device further includes a second locking component configured to engage the first locking component and retain the self-forming adsorbing element in a predetermined structure. The second locking component may be located on the adsorbing element itself such that the adsorbing element is self-formed and self-locked in the predetermined structure. Alternatively, the device may include an end cap and the second locking structure may be located on the end cap. The device may be placed in air intake ductwork, in an extending conduit positioned between the air intake ductwork and the air outlet ductwork, or both.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows one embodiment of the disclosed air intake emission control device having an adsorbing element positioned inside an air intake duct;

FIG. 2A shows one embodiment of the disclosed air intake emission control device including a self-forming, self-locking adsorbing element;

FIG. 2B shows one embodiment of the absorbent sheet suitable for forming the self-forming, self-locking adsorbing element of FIG, 2A;

FIGS. 2C and 2D illustrates the formation of the absorbent sheet of FIG, 2B into the self-forming, self-locking adsorbing element of FIG. 2A;

FIG. 3 is an explosive view of an embodiment of the disclosed air intake emission control device showing: a self-forming adsorbing element and two one-piece end caps; and

FIG. 4 is an explosive view of one embodiment of the disclosed air intake emission control device (only one end of the device is illustrated) showing: a self-forming adsorbing element and a two-piece end cap;

FIG. 5A shows one embodiment of the disclosed air intake emission control device, including a one-piece extending conduit and a self-forming adsorbing element positioned inside the extending conduit; and

FIG. 5B shows one embodiment of the disclosed air intake emission control device, including a two-piece extending conduit and a self-forming adsorbing element positioned inside the extending conduit.

DESCRIPTION OF THE DISCLOSURE

The present disclosures now will be described more fully hereinafter, but not all embodiments of the disclosure are shown. While the disclosure has been described with reference to certain embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof

The emission control device of present disclosure tray include an adsorbing element placed inside the air intake system (AIS) ductwork. Alternatively and additionally, the device may include an adsorbing element placed in an extending conduit positioned between the air intake ductwork and the air outlet ductwork.

Reference will now be made to the drawings, wherein like numerals may refer to like components. The drawings are not necessarily drawn to scale.

FIG. 1 shows one embodiment of the disclosed emission control device with the self-forming adsorbing element positioned inside the AIS ductwork. The AIS emission control device 100 includes an air intake plate 101, an air intake duct 102 connecting to the air intake plate 101, and a self-forming adsorbing element 200 positioned inside the air intake duct 102.

A particular embodiment of the disclosed emission control device may include: an adsorbing element self-formed into a predetermined structure and comprising a first locking component; and a second locking component configured to engage with the first locking component and retain the adsorbing element in the predetermined structure. The self-forming adsorbing element may include a front edge, a hack edge, and side edges extending between the front and back edges and defining the airflow path. The first locking component may be located on the front edge, or the back edge, or both the front and back edges of the adsorbing element. The side edges may function as the wails of the disclosed device, The second locking component may have a complementary structure to the first locking component.

In some embodiments of the disclosed emission control devices, the second locking component may be positioned on the adsorbing element. Therefore, the adsorbing element can include a first locking component and a second locking component engaging the first locking component to retain the adsorbing element in the predetermined structure. In these embodiments, the adsorbing element is self-formed and self-locked in the predetermined structure. The second locking component may have a complementary structure to the first locking component. FIG. 2 shows a non-limiting example of such self-forming, self-locking adsorbing elements.

As shown in the embodiment of FIG. 2A, the emission control device may comprise a self-forming, self-locking adsorbing element 200 positioned in the ductwork with an intake air flowing along its longitudinal axis. The adsorbing element 200 may be formed from an adsorbent sheet 300 of FIG. 2B. The adsorbent sheet 300 includes a first end 301, a second end 302, a first locking component 303 on the first end 301, and a second locking component 304 at a predetermined distance from the first locking component 303. FIGS. 2C and 2D illustrate a formation of the adsorbent sheet 300 into a predetermined hollow cylindrical absorbing element 200 having a radial axis and a longitudinal axis. The adsorbent sheet 300 can be rolled such that the first locking component 303 and the second locking component 304 engage each other and secure the adsorbent sheet 300 in a hollow cylindrical structure. The resulting adsorbing element 200 may he placed in a plane along an intake airflow, such that the intake air flows along the longitudinal axis of the absorbing element 200. The length (i.e., longitudinal axis) of the hollow cylindrical adsorbing element 200 may be modified by varying the width of the adsorbent sheet 300. The diameter (i.e., radial axis) of the hollow cylindrical adsorbing element 200 may be modified by adjusting the distance between the first and second locking components 303, 304. In FIG. 2, the first locking component 303 includes a tap structure and the second locking component 304 includes a complementary slot structure to engage the first locking component and retain the adsorbing element 200 in the predetermined hollow cylindrical structure.

In some embodiments, the disclosed emission control device may comprise: a self-forming adsorbing element including a first locking component on at least one of the front edge and back edge; and an end cap including a second locking component. The first locking component of the adsorbing element engages the second locking component of the end cap to retain the adsorbing element in a predetermined structure. The first locking component may have a complementary structure to the second locking component. FIGS. 3 and 4 illustrate non-limiting examples of such embodiments.

Referring to the embodiment represented in FIG. 3, the disclosed emission control device may include: an adsorbing element 200 having a front edge 301, a back edge 302, and side edges 303 extending between the front and back edges 301, 302 and defining an airflow path; a first end cap 401 connecting to the front edge 301; and a second end cap 405 connecting to the second edge 302. The first edge 301 includes a first locking component 301 a, and the second edge 302 includes a third locking component 302 a. The first end cap 401 includes a base rim 402 in a press-fit engagement with an inner perimeter of the front edge 301 and a second locking component 403 positioned on the base rim 402. When desired, the first end cap 401 may further include an extending rim 404 connecting to the base rim 402 and being adapted to abut the first edge 301 of the adsorbing element to limit an extent which the first end cap 401 may extend into the hollow cylindrical structure of the adsorbing element 200. The second end cap 405 includes a base rim 406 in a press-fit engagement with an inner perimeter of the back edge 302 of the adsorbing element and a fourth locking component 407 positioned on the base rim 406. When desired, the second end cap 405 may further include an extending rim 408 connecting to the base rim 406 and being adapted to abut the back edge 302 of the adsorbing element to limit an extent which the second end cap 405 may extend into the hollow cylindrical structure of the adsorbing element 200.

The self-forming adsorbing element 200 can be positioned in the disclosed emission control device such that an intake air flows along a longitudinal axis of the adsorbing element. The first locking component 301 a engages the second locking component 403 of the first end cap 401 to secure the first end cap 401 to the front edge 301 of the adsorbing element 200 and retain the self-forming adsorbing element in the predetermined structure. The third locking component 302 a engages the fourth locking component 407 of the second end cap 405 to secure the second end cap 405 to the back edge 302 of the adsorbing element 200 and retain the self-forming adsorbing element in the predetermined structure. In FIG. 3, the locking components 301 a and 302 a on the adsorbing element include a slot structure. The locking components 403 and 407 on the end caps include a complementary protrusion structure to engage the locking components of the adsorbing element and retain the adsorbing element in the predetermined structure.

When desired, the first locking component on the front edge and the third locking component on the back edge of the adsorbing element may have same structure. Additionally, the second locking structure on the first end cap and the fourth locking structure on the second end cap may have the same structure. For example, as shown in FIG. 3, the first locking component 301 a and the third locking component 302 a of the absorbing element 200 may have a slot structure. The second locking component 403 on the first end cap 401 and the fourth locking component 407 on the second end cap 402 may have a protrusion structure.

FIG. 4 illustrates another embodiment of the disclosed emission control device including a self-forming adsorbing element 200, wherein only the front edge of the adsorbing element is shown. The adsorbing element 200 includes a front edge 301, a back edge, and side edges 303 extending between the front and back edges and defining an airflow path. The front edge 301 includes a first locking component 301 a. The disclosed device further includes a first end cap 500 connecting to the front edge 301 and retaining the adsorbing element 200 in a predetermined structure. The first end cap 500 may comprise: an inner band 501 wrapping around an interior surface of the front edge 301 and including a third locking component 503; and an outer band 502 wrapping around an exterior surface of the front edge 301 and including a second locking component 504. The first locking component 301 a on the front edge 301 of the adsorbing element aligns with the third locking, component 503 on the inner band. The first and third locking components 301 a, 503 engage the second locking component 504 to secure the first end cap 500 to the front edge 301 and to retain the adsorbing element 200 in the predetermined structure. The first and third locking components may have complementary structure to the second locking component. For example, as shown in FIG. 4, the first and third locking components have slot structures and the second locking component has a complimentary protrusion structure.

In one embodiment of the aforementioned device of FIG. 4, the adsorbing element may include a fourth locking component on its back edge. The device may further include a second end cap connecting to the hack edge of the adsorbing element and comprising a fifth locking component configured to engage the fourth locking component to retain the self-forming adsorbing element in the predetermined structure.

In one embodiment of the aforementioned device of FIG. 4, the adsorbing element may include a fourth locking component on its back edge. The device may further include a second end cap connecting to the hack edge of the adsorbing element. The second end cap may include: an inner band wrapping around an interior surface of the back edge and comprising a locking component, and an outer band wrapping around an exterior surface of the back edge and comprising a locking component. The fourth locking component on the back edge of the adsorbing element may engage the locking component on the inner band and the locking component on the outer band of the second end cap to secure the second end cap to the back edge of the self-forming adsorbing element and to retain the adsorbing element in the predetermined structure. When desired, the locking component on the front edge and the locking component on the back edge of the absorbing element may have the same or similar structure. Additionally, the locking component on the first end cap and the locking component the second end cap may have the same or similar structure.

Although the illustrated figures show the adsorbing element in a hollow cylindrical shape, one of ordinary skill in the art understands that the disclosure is readily applicable to the adsorbing elements of other structures, shapes, or sizes. Non-limiting examples of other structures are rectangular, square, oblong, and the like. Different designs of the adsorbing element may be chosen to provide a predetermined air flow resistance and adsorbent surface area for the intended applications.

A variety of complementary structures may be used for the locking components of present disclosure. For example, referring to FIG. 2, the first locking component 303 may be a tab structure and the second locking component 304 may be a slot structure, or vice versa. Referring to FIGS. 3 and 4, the first locking component 301 a may be a slot structure and the second locking component 403 may be a protrusion structure, or vice versa. One of ordinary skill in the art understands that other complementary structures having different sizes, configurations, shapes, orientations, and positions could alternatively be employed, and the scope of the disclosure is not limited to the specific sizes, configurations, shapes, orientations, and positions shown in the representative figures.

The disclosed adsorbing element may be positioned inside the air intake ductwork, or in the extending conduit positioned between the air intake ductwork and the air outlet ductwork, or combinations thereof As shown in FIG. 1, the adsorbing element absorbent may be positioned inside the air intake ductwork. As shown in FIG. 5, the adsorbing element may be placed in an extending conduit positioned between the AIS ductwork and the air outlet ductwork.

Referring to FIG. 5, the emission control device may include an air intake plate 101, an air intake duct 102 having one end connecting to the air intake plate 101, an extending conduit 600 connecting to the other end of the air intake duct 102, and a self-forming adsorbing element 200 positioned inside the extending conduit 600. The extending conduit 600 may be a one-piece structure as shown in FIG. 5A. Alternatively, the extending conduit 600 may consist of more than one piece. One non-limiting example of such alternatives is illustrated in FIG. 5B, wherein the extending conduit 600 is consisted of an inner conduit 601 and an outer conduit 602 wrapping around the inner conduit 601. The self-forming adsorbing element may be positioned inside the inner conduit 601 of the extending conduit. Alternatively, the self-forming adsorbing element may be placed between the inner conduit 601 and the outer conduit 602 of the extending conduit 600. Although the conduit is illustrated as a cylinder in the figures, it is understood that the extending conduit may have any appropriate alternative design.

In one embodiment, the adsorbing element may comprise a substrate and an adsorbent. The substrate may be derived from a variety of materials. Non-limiting examples of suitable substrates may include paper, plastic, foam, composite, membrane, woven materials, non-woven materials, or combinations thereof. Many known adsorbents may be used in the present disclosure. Examples of adsorbents include, but are not limited to, activated carbon, charcoal, zeolite, kaolin, titania, ceria, or combinations thereof. Examples of the carbon forms suitable for use in the present disclosure may include, but are not limited to, fibers, particulates, or combinations thereof. Activated carbon suitable for use in the present disclosure may be derived from various carbon sources. Non-limiting examples of carbon sources may include wood, wood dust, wood flour, cotton linters, peat, coal, coconut, lignite, carbohydrates, petroleum pitch, petroleum coke, coal tar pitch, fruit pits, fruit stones, nut shells, nut pits, sawdust, palm, vegetables such as rice hull or straw, synthetic polymer, natural polymer, lignocellulosic material, or combinations thereof. Furthermore, the activated carbon may be produced using a variety of processes including, but not limited to, chemical activation, thermal activation, or combinations thereof.

In one embodiment, the adsorbing element may comprise an activated carbon sheet.

The end cap may be formed from various materials including, hut not limited to, plastic, rubber, composite. stainless steel, aluminum, powder coated metal, or the like.

A variety of materials may be used for the extending conduit including, but not limited to: plastics such as polyolefin, polystyrene, polyurethane, nylon, polypropylene; composite; rubber; stainless steel; aluminum; powder coated metal; and the like.

When desired, the disclosed emission control device may further include a filter for removing particulate matters from a fluid stream during an operation of the internal combustion engine.

During engine operation, the fluid stream flows through the disclosed emission control device that is in communication with an engine combustion chamber or chambers through a carburetor or intake manifold. In this manner, the intake air flows through the disclosed device prior to being introduced to a combustion chamber. After the engine shutdown, the contaminant-laden air stream from the combustion chamber may backflow through into the disclosed device. Any hydrocarbons vapor accumulating in the disclosed device or migrating from the intake manifold will pass through the adsorbing element of the device, and the hydrocarbon vapors in the contaminant-laden air are adsorbed onto the adsorbing element before the treated air is discharged to the atmosphere. Once the engine is turned on, fresh air from the external environment flows into the disclosed device, desorbs some of the previously adsorbed hydrocarbons on the adsorbing element, and carries these hydrocarbon vapors through to the combustion chamber, wherein the fluid will be combusted along with the fuel.

The contaminants in the laden fluid stream may include, but are not limited to, saturated and unsaturated hydrocarbons utilized in fuels and byproducts caused by combustion; certain carbon oxides such as carbon monoxide, nitrates, sulfides, ozone, and the like; or combinations thereof.

The emission control device of the present disclosure may be for use in removing residual fuel vapor, after the engine has been turned off, from within an engine's intake system or downstream of a throttle body.

When desired, the disclosed emission control device may be used in combination with other known air intake emission control devices. Examples of the supplemental air intake emission control devices suitable for use with the disclosed device include, but not limited to, a flow-by air intake emission control device with an adsorbing element locating in an air duct, a flow-through air intake emission control device having an adsorbing element locating in an air duct, and combinations thereof.

The disclosed emission control device may have enhanced adsorption efficiency for hydrocarbons emitted from an engine's intake manifold into an atmosphere during engine shutdown without substantially imparting airflow resistance to the air induction system, while exhibiting an improved structural integrity.

It will be recognized that as used herein, directional references such as “front”, “back”, “end”, “side”, “inner”, and “outer” do not limit the respective components to such orientation, but merely serve to distinguish these components from one another.

While the disclosure has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not he limited to the described embodiments, but will have full scope defined by the language of the following claims. 

We claim:
 1. An emission control device for an air intake system, comprising: an adsorbing element including a front edge, a back edge, and side edges extending between the front and back edges and defining an airflow path, the adsorbing element being self-formed into a predetermined structure, the adsorbing element comprising a first locking component on at least one of the front edge and the back edge; and a second locking component engaging the first locking component and retaining the self-forming adsorbing element in the predetermined structure.
 2. The device of claim 1, wherein the second locking component is located on the adsorbing element such that the adsorbing element is self-formed and self-locked in the predetermined structure.
 3. The device of claim 2, wherein the first locking component has a complementary structure to the second locking component.
 4. The device of claim 3, wherein the first locking component includes a slot structure and the second component includes a complementary tab structure.
 5. The device of claim 2, wherein the adsorbing element is formed from an adsorbent sheet having a first end and a second end opposite to the first end, the adsorbent sheet comprising a first locking component on the first end and a second locking component at a predetermined distance from the first locking component.
 6. The device of claim 1, further comprising: an end cap including a base rim, the second locking component being positioned on the base rim of the end cap.
 7. The device of claim 6, wherein the first locking component has a complementary structure to the second locking component.
 8. The device of claim 7, wherein the first locking component includes a slot structure and the second component includes a complementary protrusion structure.
 9. The device of claim 6, wherein the base rim of the end cap is in a press-tit engagement with an inner perimeter of the at least one of the front edge and the back edge of the adsorbing element.
 10. The device of claim 6, wherein the end cap further includes an extending rim connecting to the base rim.
 11. The device of claim 1, further comprising: a first end cap, the second locking component being positioned on he first end cap; and a second end cap including a fourth locking component, wherein the adsorbing element comprises the first locking component on the front edge and a third locking component on the back edge, and the first locking component on the front edge of the adsorbing element engages the second locking component of the first end cap and the third locking component on the back edge of the adsorbing element engages the fourth locking component of the second end cap to retain the adsorbing element in the predetermined structure.
 12. The device of claim 11, wherein the first locking component has a complementary structure to the second locking component.
 13. The device of claim 11, wherein the third locking component has a complementary structure to the fourth locking component.
 14. The device of claim 1, further comprising an end cap including: an outer band wrapping around an exterior surface of the at least one of the front edge and the back edge of the adsorbing element, the second locking component being positioned on the outer band; and an inner band located within an interior surface of the at least one of the front edge and the back edge, the inner hand comprising a third locking component, the first locking component on the at least one of the front edge and the back edge of the adsorbing element engaging the third locking component on the inner band of the end cap and the second locking component on the outer band of the end cap to retain the adsorbing element in the predetermined structure.
 15. The device of claim 14, wherein the first locking component has a complementary structure to the second locking component.
 16. The device of claim 14, wherein the first locking component has the same structure as the third locking component.
 17. The device of claim 1, wherein the adsorbing element comprises a substrate and an adsorbent.
 18. The device of claim 17, wherein the substrate includes a member selected from the group consisting of paper, plastic, foam, composite, membrane, and combinations thereof.
 19. The device of claim 17, wherein the absorbent includes a member selected from the group consisting of activated carbon, charcoal, zeolite, kaolin, titania, ceria, and combinations thereof.
 20. The device of claim 1, wherein the adsorbing element comprises an activated carbon sheet.
 21. The device of claim 1 further comprising a filter for removing particulate matters.
 22. The device of claim 1 positioned inside an air intake duct of the air intake system.
 23. The device of claim 1, further comprising: an extending conduit having one end connecting to an air intake ductwork and the other end connecting to an air outlet ductwork, the adsorbing element positioned in the extending conduit.
 24. An air intake system for an internal combustion engine, comprising the device of Claim
 1. 25. An emission control device for an air intake system, comprising: an adsorbing element including a front edge, a back edge, and side edges extending between the front and back edges, the side edges forming a wall of the adsorbing element and defining an airflow path along a longitudinal axis of the adsorbing element, the adsorbing element being self-formed into a predetermined structure, the adsorbing element comprising a first locking component on at least one of the front edge and the back edge; and a second locking component having complementary structure to the first locking component and being configured to engage the first locking component. 